Article carrier

ABSTRACT

An article carrier comprises a primary panel and a first side panel connected together along a first fold line. The primary panel has at least one article receiving aperture for receiving a tapered article. The at least one receiving aperture is in a tangential contacting relationship with the first fold line.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Application No. 61/116,878, filed Nov. 21, 2008, the entirety of which is incorporated herein by reference.

TECHNICAL FIELD

This invention relates to packaging articles, and more specifically, to a carrier for articles each having tapered bottoms.

BACKGROUND OF THE INVENTION

Article carriers are known in the art, and desirably facilitate a visually appealing packaging alternative, while providing convenience for transporting and supporting articles. Some article carriers are constructed to transport and support tapered articles (e.g., cans, bottles and cups) each having a top and/or bottom narrower than the other part of that article. Such carriers generally include top and bottom walls, one or both with opening, and perimeter walls for retaining the articles in contact with the bottom wall. Yet, the walls do not fully enclose the articles, thus providing inadequate support when transporting the articles. Additionally, the height of the perimeter walls is usually less than the height of the articles so as to expose the articles. This type of carrier also may include a handle or other means for lifting the carrier, the handle extending above the tops of the upright articles. Conversely, a carrier that is capable of transporting or supporting tapered articles may also include top and bottom walls with apertures and perimeter walls, but the perimeter walls are generally equal in height to the enclosed articles. Due to the height of the perimeter walls, this type of article generally does not have a handle, but requires one to hold the entire carrier or use only the finger apertures along the top surface of the carrier. Thus, the height of the perimeter walls limit the extent to which it is possible to display a tapered article and the extent to which one may carry the carrier and the enclosed articles.

There is therefore a need for a carrier that can adequately support tapered articles and also provide maximum visibility of the articles.

SUMMARY OF THE INVENTION

The present invention with its various embodiments provides a carrier that will visually expose articles such as cans, bottles, cups, etc. while maintaining them stability and portability. The carrier may have closed ends, thereby providing additional support and increased strength to the carrier and the loaded articles.

According to one aspect of the present invention, the carrier is formed from a blank. The blank has a plurality of panels including a primary/top panel with a center longitudinal slot, a pair of base panels, and a pair of side panels which are hingedly connected to the top panel and to the respective base panels along fold lines. Hingedly connected to each of the base panels and the top panel is a pair of opposing end panels or flaps. A pair of end flaps may also be hingedly connected to each side panel of the carrier as well in certain embodiments to provide more support for the closed ends. When the carrier is assembled, the end flaps overlap to form the closed ends. Additionally, an insert panel with means for supporting the top panel may be foldably attached along a fold line to one of the opposed side edges of at least one of the base panels.

The top panel may includes a plurality of receiving apertures that are positioned, in the embodiments, in a grid-like pattern with each receiving aperture being equal distance apart from each adjacent receiving aperture. However, it is contemplated that the apertures may be arranged in any suitable pattern, regular or irregular. Each base panel may also include a plurality of base apertures positioned side by side in a grid. When the carrier is assembled, the pair of base panels forms a composite base panel, and the base apertures are vertically aligned beneath the receiving apertures of the top panel. Each base aperture has a continuous edge and may have at least two legs hingedly connected along the continuous edge of each base aperture. The receiving apertures and the base apertures are positioned in registry with one another to cooperatively support articles, specifically a tapered article including wide mouth containers. As used herein, the term “tapered article” refers to a container having a top or bottom the circumference or cross section of which less than that of the remainder of the article. The term “wide mouth container” refers to a container having an opening the circumference or cross-section of which is relatively larger than that of its base. For example, a wide mouth container may be a flared cylinder with outwardly sloping walls. The legs of the base apertures may extend obliquely from the edge of the base apertures when a container is placed into the receiving aperture and subsequently into the base aperture. In this position, the legs support the articles and maintain the stability of the carrier.

The carrier includes a handle that is formed from the insert panel described above. The handle extends upright through the slot in the top panel while the means for support prevents the handle from passing completely through the slot. The handle therefore provides a means for transporting the carrier and supporting the structural integrity of the carrier. Optionally, the handle is strengthened with one or more hingedly connected overlays that form a multi-ply composite handle. The handle also includes an aperture with a foldably attached cushioning flap for comfort and ease when the carrier is being carried. In alternate embodiments, the handle may be strengthened by using a stronger material for the insert panel or by laminating the insert panel. The handle aperture can be replaced with an ergonomically shaped handle that provides a comfortable hand-hold, such as a T-shaped handle.

In other alternative embodiments, the carrier may be modified to accommodate additional or fewer articles. The blank for a larger carrier, for example, would include larger panels and side panels to accommodate more receiving apertures and base apertures or smaller panels and side panels for fewer receiving apertures and base apertures. The blank for a carrier of larger articles might have fewer and larger receiving apertures and base apertures. The number or size of insert panels may increase or decrease.

Accordingly, the foregoing has broadly outlined some of the aspects and features of the present invention, which should be construed to be merely illustrative of various potential applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by combining various aspects of the disclosed embodiments. Other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a blank for forming a carrier in accordance with an exemplary embodiment of the invention;

FIG. 2 is a perspective view of the carrier formed from the blank of FIG. 1.

FIG. 3 is a perspective view of a carrier of a second embodiment loaded with tapered articles;

FIG. 4 is a perspective view of a blank for forming a carrier of a third embodiment; and

FIG. 5 is a perspective view of a blank for forming a carrier of a fourth embodiment.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosed herein. It will be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known materials or methods have not been described in detail in order to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not limiting but serve as a basis for the claims and for teaching one skilled in the art to variously employ the present invention.

Referring now to the drawings in which like numerals indicate like elements throughout the several views, the drawings illustrate certain of the various aspects of an exemplary embodiment of a carrier that is formed from a blank according to the present invention. The blank and carrier are formed from paperboard or other foldable sheet material, for example plastics material or the like, to which there has been added cut and fold lines. The carrier is used to hold and visually expose articles while maintaining stability and portability of the articles. In the illustrated embodiment, a unitary blank is used to make a single carrier, although it is foreseen that two or more blanks may be combined for example to form the carrier.

Referring to FIG. 1, there is shown a blank 10 for constructing a carrier with closed ends. For the purposes of reference, the side of the blank 10 shown in FIG. 1 is defined as the outside surface, and the opposing side of the blank 10 is defined as the inside surface. The blank 10 includes an insert panel 15, a first base panel 20, a first side panel 25, a primary panel in the form of a top panel 30, a second side panel 35, and a second base panel 40. Each of the panels 15, 20, 25, 30, 35, and 40 is foldably connected at side edges along transverse fold lines 18, 22, 28, 32, 38, and 42 to each subsequent panel. In this exemplary embodiment, the blank 10 also includes base flaps 2 a, 2 b, 2 c, and 2 d, end panels or flaps 4 a, 4 b, 4 c, 4 d and top flaps 6 a and 6 b foldably connected at the respective longitudinal fold lines 19 a, 19 b, 21 a, 21 b, 23 a, 23 b, 24 a, 24 b, 27 a, and 27 b along the end edges of the respective base panels 20, 40, side panels 25, 35, and the top panel 30. The end flaps 4 a, 4 b, 4 c, and 4 d are separated from the base flaps 2 a, 2 b, 2 c, and 2 d and top flaps 6 a and 6 b by means of cuts 61 a, 61 b, 63 a, 63 b, 65 a, 65 b, 67 a and 67 b. Those skilled in the art will recognize that any of the flaps could also be connected via web panels. Furthermore, the end flaps 4 a, 4 b, 4 c, and 4 d could be omitted from the blank 10 without jeopardizing the ability to enclose the ends of the carrier as will be discussed in further detail below.

The insert panel 15 is foldably attached along fold line 18 to the first base panel 20 and includes means for support, depicted as shoulders 70 a and 70 b in this embodiment. An overlay 75 hingedly connects to an edge of the insert panel 15 along fold line 14, which extends from the distal edge of the insert panel to the upper extent of the shoulder 70 a. The overlay 75 strengthens the insert panel 15 by providing greater rigidity when the carrier is formed and the insert panel 15 is used as a handle A (See FIG. 2). It is, however, contemplated that the insert panel 15 may be strengthened instead or additionally by using a stronger material or by laminating the insert panel. In the illustrated embodiment, the overlay 75 is a mirror image of a portion of the insert panel 15. Furthermore, each panel has a complementary aperture 80, 90 with foldably connected aperture flaps 85 and 95, all of which align when the overlay 75 is secured to the insert panel 15, as will be described in greater detail below.

As further shown in FIG. 1, the first 20 and second base panels 40 each include a plurality of base apertures 45 which are situated side by side and equal distances apart. In other words, the base apertures 45 are arranged in a matrix like formation having uniform columns and rows, although other arrangements are foreseeable. Connected along the continuous edge of each aperture 45 and hingedly attached along fold lines 47 are legs 50. In the embodiment illustrated in FIG. 1, multiple legs are hingedly attached to the base apertures 45. Specifically, innermost ones of the base apertures 45 include three legs 50 attached thereto and outermost ones of the base apertures 45 include two legs 50 attached thereto. However, in alternative embodiments, legs 50 can be omitted from any of the base apertures 45, a single leg 50 can be hingedly attached to any of the base apertures 45, and multiple legs 50 can be hingedly attached to any of the base apertures 45. In general, a sufficient number of legs 50 is selected so as to adequately balance and/or support a tapered article B (shown in FIG. 3) when the carrier is formed and loaded. Those skilled in the art understand that the number of legs may vary by design.

Additionally, the legs 50 may be positioned so as not to obstruct the view of articles B when the carrier is loaded. For example, referring to the embodiment illustrated in FIG. 1, the legs 50 are so positioned so as to be hingedly attached to the portion of the edge of the apertures 45 that is innermost. The innermost portion of the edge of the aperture 45 can be described as that which is not adjacent or tangentially contacting the edges of the base panels 20, 40, which are defined by the fold lines 18, 19 a, 19 b, 22, 27 a, 27 b, 38, 42.

The second base panel 40 also includes a support flap 65 foldably connected to the side edge of the second base panel 40 along fold line 42. The top panel 30 includes a transversely extending elongated slot 60 centrally positioned therein and a plurality of receiving apertures 55 which are juxtaposed equal distance apart. Like the base apertures 45, the receiving apertures 55 are arranged in a complementary matrix-like formation with uniform columns and rows.

From the blank 10 described above, the exemplary carrier 100 of FIG. 2 may be formed. The following method of forming the carrier is provided for purposes of teaching and not for limitation, so it should be understood that any of the steps described below may or may not be used in this method and may be followed in any order. To erect the exemplary carrier 100, the overlay 75 is folded along the fold line 14 into a face contacting relation with the insert panel 15 so that the inner surface of the overlay 75 contacts the inner surface of the insert panel 15 to form a composite handle A. The insert panel 15 and the overlay 75 are secured together by any means of securing known or yet to be developed, such as, but not limited to glue or staples. It is, however, not required that the overlay 75 and insert panel 15 be securely fastened to one another. Rather, the slot 60 may be sufficiently narrow to maintain a close relation between the insert panel 15 and the overlay 75.

Once assembled, the composite handle A is folded inwardly along the fold line 18 and then the distal end of the handle A is positioned and inserted into the longitudinal slot 60 of the top panel 30. The first base panel 20 consequently is folded inwardly along the fold line 22 and the first side panel 25 is folded inwardly along the fold line 28. Alternatively, the blank is folded along the fold line 28 so that the side panel 25 is substantially perpendicular to the top panel 30. Then the first base panel 20 is folded along the fold line 22 until the first base panel is substantially parallel to the top panel 30, with the base apertures 45 in registry with the receiving apertures 55. The handle A is pulled through the slot 60 until the shoulders 70 a and 70 b of the handle A lodge against the ends of the elongated slot 60 in the top panel 30. The width of the shoulders 70 a and 70 b is greater than the width of the longitudinal slot 60 to provide support for the top panel 30 and to maintain the desired spacing from the base panels 20, 40. In a similar manner, on the opposite side, the second base panel 40 is folded inwardly along the fold line 38 and the second side panel 35 then folds inwardly along the fold line 32 toward the top panel 30 until the outer surface of the support flap 65 comes into proximity to the shoulders of the insert panel 15. The outer surface of the support flap 65 is secured to the shoulders 70 a and 70 b of the insert panel 15 by a suitable means of securing known or yet to be known in the art, such as glue or staples. Consequently, the inside surfaces of the first and second base panels, the first and second side panels, and the top panel face one another.

The first 20 and second base panels 40 substantially coplanar and together form a composite base panel 20/40 that underlies the top panel 30. Once the panels 20/40, 25, 30, and 35 are substantially in place, the base flaps 2 a, 2 b, 2 c, and 2 d are folded inward and upward along fold lines 19 a, 19 b, 27 a, and 27 b, the end flaps 4 a, 4 b, 4 c, and 4 d are folded inward along fold lines 21 a, 21 b, 24 a, and 24 b, and the top flaps 6 a and 6 b are folded downward along fold lines 23 a and 23 b. The outside surfaces of the flaps 2 a, 2 b, 2 c, 2 d, 4 a, 4 b, 4 c, 4 d, 6 a, and 6 b are then substantially overlapped in any order to form the closed ends 110 a, 100 b (FIG. 2) of the carrier 100. The flaps are securely fastened to one another by a suitable means of securing. The closed ends 110 a, 110 b, along with the shoulders 70 a and 70 b that support the top panel 30, are elements of the support system for the carrier 100 that establish and maintain the structural integrity and ensure that the carrier 100 is plumb and stable.

The receiving apertures 55, depicted in FIG. 2, are positioned in registry with respective ones of the base apertures 45 for receiving articles. In the embodiment illustrated in FIGS. 1 and 2, certain of the receiving apertures 55 are tangentially in contact with one or more fold lines 23 a, 23 b, 28, and 32 so as to allow an article B (such as shown in FIG. 3) to contact or touch the inside surface of the respective flap 2 a, 2 b, 2 c, 2 d, 4 a, 4 b, 4 c, 4 d, 6 a, 6 b or side panel 25 or 35. Referring to FIG. 1, certain of the receiving apertures 45 are also tangentially in contact with one or more fold lines 19 a, 19 b, 22, 38, 27 a and 27 b so as to allow an article B (such as shown in FIG. 3) to contact or touch the inside surface of the respective flap 2 a, 2 b, 2 c, 2 d, 4 a, 4 b, 4 c, 4 d, 6 a, 6 b or side panel 25 or 35. Thus, the article B and respective flap 2 a, 2 b, 2 c, 2 d, 4 a, 4 b, 6 a, 6 b or side panel 25 or 35 support one another to improve the strength and stability of the carrier.

FIG. 3 shows an article carrier 200 of a second embodiment that has been loaded with, by example and not by way of limitation, four tapered articles B. As used herein, the term “taper” is expansively defined as to become narrower at one end. A blank for forming the carrier of this embodiment may have the sequence of panels similar to that of the panels of the blank 10. The shape and size of each panel of the blank differ from those of blank 10 in FIG. 1. However, the function of each panel of the blank is substantially similar to that of each panel of the blank 10. Thus, like reference numerals have been used to denote like features, albeit the reference numerals in FIG. 3 have been raised by a factor ‘200’ to indicate that they relate to those of the blank 10 of the first embodiment.

The carrier of the second embodiment has been modified to accommodate less articles than the carrier of the first embodiment by narrowing the top panel 230, the first and second base panels and the first and second side panels 235 (only one shown). The illustrated article B gradually becomes narrower at the base of the article B forming a relatively wide mouth. The mouth of the article B is wider than the receiving aperture 255 in the top panel 230 so that the article B will sit inside the receiving aperture 255 without falling through. At some point along the extent of the article B, the width of its neck is substantially the same as that of the receiving aperture 255, and the width of the base of the article B is substantially the same as the base aperture 245. In the exemplary embodiment, the height of the article B is greater than the height of the closed ends 206 a (only one shown) of the carrier 200 for stability of the article B when seated in the carrier 200. As used in this paragraph, the term “same” means similar in dimension, with adequate clearance allotted for insertion and removal, and sufficient contact for a bracing fit.

Returning to FIGS. 1 and 2, when the article B is placed into a receiving aperture 55 and subsequently into the base aperture 45, the leg(s) 50 surrounding the edge of the base aperture 45 are folded downwardly along the fold lines 47 and extend substantially obliquely or perpendicularly with respect to the first and second base panels 20, 40 to support the articles and the carrier 100. The vertical length of the legs 50 are generally equal to each other so that the carrier 100 is balanced and held upright while also supporting the article B.

The handle A of the loaded carrier 200 shown in FIG. 3 provides for easy transportation of the carrier 200. The handle A comprises an aperture 290 for inserting one's hand and an aperture flap 295 to enhance the comfort of the grip of handle A. If an overlay is used to strengthen the insert panel, as depicted in the first exemplary embodiment, the aperture flaps of the overlay and the insert panel may be fastened together to form a two-ply flap.

FIGS. 4 and 5 show primary blanks 300, 400 for forming carriers according to third and fourth embodiments respectively. The blanks 300 and 400 are formed from foldable sheet material similar to the one used to make blank 10 in FIG. 1. The sequence of the panels of each of the blanks 300 and 400 is similar to that of blank 10. The function of each panel of each blank 300, 400 is also substantially similar to that of the blank 10. However, the shape and size of each panel of each blank 300, 400 differ from those of blank 10. Thus, like reference numerals have been used to denote like features, albeit the reference numerals in FIG. 4 have been raised by a factor ‘300’ and the reference numerals in FIG. 5 have been raised by a factor ‘400’, so as to indicate that they relate to those of the blank 10 of the first embodiment.

Each of the blanks 300 and 400 has been modified to form a carrier (not shown) to accommodate more articles by widening the top panel 330, 430 the first and second base panels 320, 340, 420, 440, and the first and second side panels 325, 335, 425, 435. Optionally, additional or doubly reinforced insert panels 315 a, 315 b, 415 and corresponding overlays 375 a, 375 b, 475 a, 475 b can be included to support more articles. As dictated by the particular application, the dimensions of each insert panel 15, 315 a, 315 b, 415 itself is a design decision, the objective being to support the intended number, size, and configuration of articles. The dimensions of other corresponding elements, i.e., the flaps of all panels, side panels, and the slot of the top panel can be constructed in the same manner.

It must be emphasized that the above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiments without departing from the scope of the claims. All such modifications, combinations, and variations are included herein by the scope of this disclosure and the following claims. 

1. An article carrier comprising a primary panel and a first side panel connected together along a first fold line, the primary panel having at least one article receiving aperture for receiving an article, wherein the at least one receiving aperture is in a tangential contacting relationship with the first fold line.
 2. The carrier of claim 1, further comprising a first end panel hingedly connected to the primary panel along a second fold line, wherein the at least one receiving aperture is in a tangential contacting relationship with the second fold line.
 3. The carrier of claim 2, further comprises a second side panel hingedly connected to the primary panel and first and second base panels hingedly connected respectively to the first and second side panels, the first and second base panels being coplanar with each other to form a composite base panel underlying the top panel.
 4. The carrier of claim 3, wherein at least one of the first and second base panels comprises at least one base aperture, the at least one base aperture being substantially vertically aligned beneath the at least one receiving aperture.
 5. The carrier of claim 4, wherein the at least one base aperture is in a tangential contacting relationship with a fold line along which the at least one of the first and second base panels is hingedly connected to a respective of the first and second side panels.
 6. The carrier of claim 4, wherein the at least one base aperture has a continuous edge and at least one leg hingedly connected along the continuous edge.
 7. The carrier of claim 3, wherein the primary panel comprises at least one elongated slot positioned generally away form the first fold line, the carrier further comprises a handle extending substantially upward from at least one of the first and second base panels through the at least one slot, the handle comprising an insert panel hingedly connected to the at least one of the first and second base panels, the insert panel including at least one shoulder for supporting the top panel.
 8. The carrier of claim 3, further comprising a second end panel hingedly connected to the composite base panel, the first and second end panels being at least partially overlappingly secured to one another to form a closed end.
 9. The carrier of claim 7, wherein the handle further comprises at least one overlay foldably connected along a side edge of the insert panel and folded into a face contacting arrangement with the insert panel.
 10. The carrier of claim 7, wherein the width of the insert panel at the shoulder is greater than width of the elongated slot.
 11. The carrier of claim 8, further comprising third and fourth end panels foldably attached to the first and second side panels, respectively.
 12. The carrier of claim 11, wherein the first, second, third and fourth end panels overlap to form the closed end.
 13. The carrier of claim 6, wherein the at least one leg extends in a substantially oblique manner from the continuous edge of the at least one base aperture when an article is received into the corresponding receiving aperture.
 14. The carrier of claim 6, wherein the at least one leg is hingedly connected to an innermost portion of the continuous edge of the at least one base aperture such that the visibility of the at least one leg is obstructed when articles are loaded into said carrier.
 15. A blank for forming an article carrier, the blank comprising a primary panel and a first side panel connected together along a first fold line, the primary panel having at least one article receiving aperture for receiving an tapered article, wherein the at least one receiving aperture is in a tangential contacting relationship with the first fold line.
 16. The blank of claim 15, further comprising a first end panel hingedly connected to the primary panel along a second fold line, wherein the at least one receiving aperture is in a tangential contacting relationship with the second fold line.
 17. The blank of claim 16, further comprises a second side panel hingedly connected to the primary panel and first and second base panels hingedly connected respectively to the first and second side panels.
 18. The blank of claim 17, wherein at least one of the first and second base panels comprises at least one base aperture.
 19. The blank of claim 18, wherein the at least one base aperture has a continuous edge and at least one leg hingedly connected along the continuous edge.
 20. The blank of claim 17, wherein the primary panel comprises at least one elongated slot positioned generally away form the first fold line, the blank further comprises an insert panel hingedly connected to the at least one of the first and second base panels, the insert panel including at least one shoulder for supporting the top panel. 